Deformation Processing

g-
Extrusion

ver. 1

ME 6222: Manufacturing Processes and 1

Systems Prof. J.S. Colton © GIT 2009
 Overview

• Equipment
• Characteristics
• Mechanical
M h i lA Analysis
l i
– direct extrusion
– indirect extrusion
• Redundant work
• Defects

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Geometry (90o die)
p

D1 dead
d d zone
45o angle

D2

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Equipment

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Systems Prof. J.S. Colton © GIT 2009
 Extrusion

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Equipment

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Extrusions

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ME 6222: Manufacturing Processes and 8
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 Characteristics

• Similar to closed die forging

• Forging
– slug (bulk) is forging
– flash (extrusion) is waste
• Extrusion
– extrusion ((flash)) is part
p
– billet (bulk) is waste

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 Types

• Direct
• Indirect
• Tubular
• H d t ti
Hydrostatic
• Cold Impact

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 Types

1 – direct
2 – indirect
3 – heading (forging also)

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 Flow types
• “Laminar”
• “Turbulent”
– redundant work
– can bring outside of billet into
center
– leaving the skin keeps outside
scale out of final extrusion

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Systems Prof. J.S. Colton © GIT 2009
 Steel extrusion
• Tprocessing = 2100 to 2400oF (1150 – 1315oC)
• Tmelting = 2500 - 2800oF (1370 – 1540oC)
• Die ≈ 400oF (205oC)
• Obviously “Hot”
– above recyrstallization point
• Lubricants
– glass (viscous lube ) 0.001” thick
– MoS2
– graphite

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 Mechanical Analysis
x p
external
friction
D1 dead zone
45o angle

internal
D2 friction

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Systems Prof. J.S. Colton © GIT 2009
 Assumptions

• Metal deforms uniformly

– D1 to D2
• No redundant work
• Can’t use slab analysis
– die angles
g too g
great
– friction too high
• Dead zone sets up at 45 degrees

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Systems Prof. J.S. Colton © GIT 2009
 Upper bound analysis
• Work input
p by y external forces
= plastic work expended

&
W = &
W
pressure internal friction
p τfriction
&
+W plastic work to compress

&
+W external friction

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 Rate of work = Power

• Work rate = Power

• Work rate = Area • stress • velocity

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 Pressure work input

• Power = A • p • v
– ram moves at velocity, vram

π D 2
W& p = 1
⋅ p ⋅ vram
4

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 Internal “frictional” work input
p
• Work determined by integrating rate of
frictional work dissipation at each cross
section from D2 to D1
– τfriction = τflow
– vi is in xx-direction
direction

D + dD
⎛ D1 ⎞ D
⎜ ⎟
&
∫
W f = τ flow ⋅ ⎜ π vi DdL ⎟
⎜ D ⎟
dx
⎝ 2 ⎠ 45o
dL=dD/√2
dL dD/√2
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Systems Prof. J.S. Colton © GIT 2009
 Internal “frictional”
frictional work input

• Volumetric flow rate

Q = A1vram = Ai vi
– where D
D, Ai, vi are instantaneous

2
⎛ D1 ⎞
vi = ⎜ ⎟ vram
⎝D⎠

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Systems Prof. J.S. Colton © GIT 2009
Internal “frictional”
frictional work input

πvramτ flow D 2 D1
dD
W& f = ∫D D
1

2 2

πvramτ flow D12 D1

W& f = ⋅ ln
2 D2

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Systems Prof. J.S. Colton © GIT 2009
 Plastic work to compress input
• Power = up x Area x velocity
Energy / volume = u p = ∫ σ dε = 2τ flow ε
D1
ε = 2 ln
D2
• hence
h
⎛ D1 ⎞ ⎛ π D12 ⎞
∴ W& pw = ⎜⎜ 4 τ flow ⋅ ln ⎟⎟ ⋅ ⎜⎜ ⎟⎟ ⋅ vram
⎝ D2 ⎠ ⎝ 4 ⎠

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Total work input
p ((without external friction))

π D12 π D12 ⎛ D1 ⎞
⋅ p ⋅ vram = ⋅ vram ⋅ ⎜⎜ 4τ flow ⋅ ln
l ⎟⎟
4 4 ⎝ D2 ⎠
π D12 4τ flow D1
+ ⋅ vram ⋅ fl
⋅ ln
4 2 D2

• reducing
p D1
= 3.414 ⋅ ln
2τ flow D2

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 Extrusion ratio (re)

• Reduction in area (RA) is large

– it is not sensitive for classification
• Use re instead

2
⎛ D1 ⎞ 1
re = ⎜⎜ ⎟⎟ =
⎝ D2 ⎠ 1 − RA

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Systems Prof. J.S. Colton © GIT 2009
Extrusion pressure (without external friction)

2
p D1 ⎛ D1 ⎞
= 3.414 ⋅ ln = 1.707 ⋅ ln⎜⎜ ⎟
⎟
2τ flow D2 ⎝ 2⎠
D

p
= 1.707 ⋅ ln re
2τ flow

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 Billet - wall friction

• Assume limitingg case:

friction stress = shear flow stress
τf = τflow

τflow

τflow
fl

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Systems Prof. J.S. Colton © GIT 2009
Additional pressure due to billet - wall
friction

π ⋅ D1
2
Δp ⋅ = τ flow ⋅ π ⋅ D1 ⋅ x
4
τflow
Δp 2x
=
2τ flow D1 τflow

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Systems Prof. J.S. Colton © GIT 2009
 Direct extrusion pressure

px p Δp p 2x
2x
= + = +
2τ flow 2τ flow 2τ flow 2τ flow D1

px D1 2 x
= 3.414 ⋅ ln +
2τ flow D2 D1
px 2x
= 1.707 ⋅ ln re +
2τ flow D1

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Systems Prof. J.S. Colton © GIT 2009
 Indirect extrusion
• No wall- billet interaction
• Include
I l d wallll - dead
d d zone
interaction
– assume: friction stress = shear
flow stress
τf = τflow D2 τflow D1
• Same result as direct
extrusion
– without external friction dead
zone
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Systems Prof. J.S. Colton © GIT 2009
Additional pressure due to billet-
d d zone ffriction
dead i ti

Δp ⋅
π
4
⋅ ( )
D12
⎛ D1 − D2 ⎞
= τ flow ⋅ π ⋅ D1 ⋅ ⎜
⎝ 2
⎟
⎠

τflow
Δp D2
=1− D2 D1
2τ flow D1 τflow

dead
zone
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Systems Prof. J.S. Colton © GIT 2009
Indirect Extrusion Pressure

p D1 ⎛ D2 ⎞
= 3.414 ⋅ ln + ⎜⎜1 − ⎟
2τ flow D2 ⎝ D1 ⎟⎠
p ⎛ D2 ⎞
= 1.707 ⋅ ln re + ⎜⎜1 − ⎟
⎟
2τ flow ⎝ D1⎠

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 Strain hardening
(cold – below recrystallization point)

• Not plane strain (Tresca)

Kε n
2τ flow = σ flow =Y =
n +1
average flow stress:
d tto shape
due h off element
l t

ME 6222: Manufacturing Processes and 32

Systems Prof. J.S. Colton © GIT 2009
 Strain rate effect
(hot – above recrystallization point)
• Not plane strain (Tresca)
2τ flow = σ flow = Y = C (ε )
& m

where ε& = average strain rate

due to shape of element

6 v D 2
⋅ tan α 12 v ram 1 ⋅ tan α
D 2
⎛ D1 ⎞
ε =
& ram 1
⋅ ln re = ⋅ ln⎜⎜ ⎟⎟
D1 − D2
3 3
D1 − D2
3 3
⎝ D2 ⎠

6vram 12vram ⎛ D1 ⎞ (dead zone approx.

ε =
& ⋅ ln re = ⋅ ln⎜⎜ ⎟⎟ large extrusion ratio
D1 D1 ⎝ D2 ⎠ α = 45o)

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Direct vs.
vs Indirect Extrusion

Redundant
set-up
set up work
(squashing
dead zone)

a = direct,
di t b = iindirect
di t
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 Strain rate derivation
x
For a billet radius, R1, α
as a function of distance
distance, xx, from r
R1
the entrance

R1 − r r = R1 − x ⋅ tan α
tan α =
x
dA
dε = A = πr 2
dA = 2πr ⋅ dr
A
2dr dr = − tan α ⋅ dx
dε =
r
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 Strain rate derivation

dε ⎛ 2 ⋅ tan α ⎞ ⎛ dx ⎞ dx
ε& = = −⎜ ⎟⋅⎜ ⎟ = vram
dt ⎝ r ⎠ ⎝ dt ⎠ dt

2vram ⋅ tan α
ε& = −
r
flow rate is constant

v1R12
vram = 2
r
ME 6222: Manufacturing Processes and 36
Systems Prof. J.S. Colton © GIT 2009
 Strain rate

2v1R12 ⋅ tan α 2v1R12 ⋅ tan α

ε& = − =−
r3 (R1 − x ⋅ tan α )3

ME 6222: Manufacturing Processes and 37

Systems Prof. J.S. Colton © GIT 2009
 & ε
Average strain rate derivation ε =
t
Volume of deformation zone, V

πh ⎛⎜ D12D22 D1D2 ⎞⎟ 1 D1 − D2
tan α = ⋅
V= ⋅ + +
3 ⎜⎝ 4 4 4 ⎟⎠ h 2

V=
π
24
(
⋅ D1 − D2 ⋅
3 3 1
tan α
) hα
D2

D1
From the ram velocity,
y vram

V ⎛ πD1 ⎞
2
D1-D2
= vram ⋅ ⎜⎜ ⎟⎟
t ⎝ 4 ⎠
ME 6222: Manufacturing Processes and 38
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 & ε
Average strain rate derivation ε =
t
time to fill deformation zone,, t

V D13 − D23 1
t= = ⋅
⎛ πD1 ⎞ 6vram D1 tan α
2 2
vram ⋅ ⎜⎜ ⎟⎟
⎝ 4 ⎠

average strain
D12
ε = ln re = ln
D22
ME 6222: Manufacturing Processes and 39
Systems Prof. J.S. Colton © GIT 2009
 Average strain rate

6vram D ⋅ tan α
2
12vram D ⋅ tan α ⎛ D1 ⎞
2
ε =
& 1
⋅ ln re = ⋅ ln⎜⎜ ⎟⎟
1
D1 − D2
3 3
D1 − D2
3 3
⎝ D2 ⎠

Approximation for dead zone: D1>> D2 and α = 45o

6vram 12vram ⎛ D1 ⎞
ε =
& ⋅ ln re = ⋅ ln⎜⎜ ⎟⎟
D1 D1 ⎝ D2 ⎠

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 Example – 1-1
11
• You are forward, cold extruding Al-1100
Al 1100 (K =
140 MPa, n = 0.25), 10-cm diameter billet to a
diameter of 5-cm at 1 m/min. The billet is
i iti ll 25 cm llong
initially
• The ram is made of a high-strength steel with
a yield stress of 1
1.5
5 GPa
GPa.
• Determine the extrusion force and power.
• Determine the safety factor for indenting the
ram.

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Systems Prof. J.S. Colton © GIT 2009
 Example – 1-2
12

• The equations we use are:

px D1 2 x
= 3.414 ⋅ ln
l +
2τ flow D2 D1
because
Kε n
2τ flow =Y = Kε
n +1 u p = ∫ σdε = ∫ Kε dε = n

n +1
⎛ D1 ⎞
ε = 2 ln⎜⎜ ⎟⎟
⎝ D2 ⎠

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 Example – 1-3
13
• We need to determine the dead-zone length to
subtract
bt t from
f the
th initial
i iti l billet
bill t llength.
th

• so l = 0.25 – 0.025 = 22.5 cm

45°

2.5 cm
5 cm
2 5 cm
2.5

2 5 cm
2.5

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 Example – 1-4
14
• Substituting values
⎛ D1 ⎞ ⎛ 10 ⎞
ε = 2 ln⎜⎜ ⎟⎟ = 2 ln⎜ ⎟ = 1.39
⎝ D2 ⎠ ⎝5⎠
Kε n 140 × (1.39 )
0.25
2τ flow =Y = = = 121.6 MPa
n +1 0.25 + 1

⎛ D1 2 x ⎞
px = 2τ flow × ⎜⎜ 3.414 ⋅ ln + ⎟⎟
⎝ D2 D1 ⎠

⎛ 10 2 × 22.5 ⎞
Pextrusion , max = 121.6 × ⎜ 3.414 ⋅ ln + ⎟ = 834 MPa
⎝ 5 10 ⎠
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 Example – 1-5
15
π
Fextrusion = Pextrusion × Area = 834 × 10 × 6
(0.1) 2
= 6.6 MN
4
Power = F × speed
p = 6.6 MN × 1m / min× min/ 60 sec = 110kW

• Safety factor against indenting the ram

– to determine the “press
“press-fit”
fit” failure
failure, we would
need the dimensions of the extrusion die and its
material
σy 1.5 GPa
n= = = 1 .8
σ extrusion , max 0.834 GPa

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Systems Prof. J.S. Colton © GIT 2009
 Redundant work

• Δ = dm/L p
• dm = (D1 + D2) / 2
D1
• p = Qr σflow

L (contact length) D2

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 Redundant work factor (Backofen)
( )
(frictionless)

Qr =

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 Defects
• Surface materials drawn
into center
–p
pipe,
p , tail p
pipe
p

• Surface materials
extruded
– eliminate by leaving
skin

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Chevron Cracking

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 Chevron cracking
g defect

• Hydrostatic tension
– outer layer in compression
– inner layer in tension
tension, if
entire part is not plastic
• eliminate by using a fluid
– hydrostatic compression
– reduces
d ffriction
i ti

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 Defects

• Surface speed cracking

– high friction
– temperature
– speed

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 Summary
• Equipment
• Characteristics
• Mechanical Analysis
– direct extrusion
– indirect
i di extrusion
i
• Redundant work
• Defects

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ME 6222: Manufacturing Processes and 53
Systems Prof. J.S. Colton © GIT 2009